Sears 200.71230 User manual

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.

BATTERY CHARGER

40/2 Amp

Manual

200 Amp

ENGINE STARTER

00-99-000312/0306

Model No.

200.71230

OWNER’S MANUAL

CAUTION:

Read all Safety Rules and Operating Instructions,

and follow them with each use of this product.

Warranty .................................................................... 1

Important Safety Instructions ................................. 2

Parts .......................................................................... 3

Before Using Your Battery Charger ........................ 4

Assembling your charger ..................................... 4

Plugging it in ........................................................ 5

Using an extension cord....................................... 6

Preparing your battery to be charged .................. 6

Using Your Battery Charger..................................... 7

Setting the controls .............................................. 7

Charging your battery .......................................... 8

Calculating charge times .................................... 10

Using the engine start feature ............................ 11

Maintenance and care ....................................... 11

Troubleshooting ..................................................... 12

Please read this Owner's Manual before using your Battery Charger

The DieHard model 71230 Manual Battery Charger/Engine Starter, offers a wide range of features to

accommodate the needs for home or light commercial use. This manual will show you how to use your

charger safely and effectively. Please read and follow these instructions and precautions carefully.

For information about troubleshooting, call toll-free from anywhere in the U.S.A. 7 am to 4:30 pm Central

Time Monday through Friday. 1-800-SEARS-64 (1-800-732-7764).

Table Of Contents

Warranty

THREE-YEAR FULL WARRANTY

If this Battery Charger fails due to a defect in material or workmanship within three years from the date of

purchase, RETURN IT TO ANY SEARS STORE or OTHER DIEHARD OUTLET IN THE UNITED STATES

FOR FREE REPLACEMENT.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to

state.

Sears, Roebuck and Co.

Hoffman Estates, IL 60179

Help us help you

Remember:

• Place charger as far away from battery being

charged as the charger cables will permit.

• Do not expose charger to rain or snow.

• Never charge a frozen battery. If battery fluid

(electrolyte) becomes frozen, bring battery into a

warm area to thaw before you begin charging.

• Never allow battery acid to drip on charger when

reading specific gravity or filling battery.

• Never set a battery on top of the charger.

• Never place charger directly above battery being

charged. The gases from the battery will corrode

and damage the charger.

• Never use charger for charging dry-cell batteries

that are commonly used with home appliances.

These batteries may burst and cause personal

injury.

• Never touch the battery clamps together when the

charger is energized.

• Never operate charger if it has received a hard blow,

been dropped, or otherwise damaged. Take it to a

qualified professional for inspection and repair.

• Be sure to position the charger power cord to

prevent it from being stepped on, tripped over, or

damaged.

• Never pull out the plug by the cord when unplugging

the charger. Pulling on the cord may cause damage

to the cord or the plug.

• Do not operate the charger if it has a damaged

power cord or plug. Have the cord replaced.

Personal Safety Precautions

For your own personal safety, please follow the

following precautions:

Important Safety Instructions

To reduce the risk of explosion, explosive gases, or injury while

using your battery charger, follow the precautions listed below:

• Read all instructions and cautions printed on the

battery charger, battery, and vehicle or equipment

using battery.

• Use charger only on lead-acid type rechargeable

batteries, such as those used in cars, trucks,

tractors, airplanes, vans, RVs, trolling motors, etc.

This charger is not intended to supply power to a

low voltage electrical system other than in an

automotive application.

• Use only attachments recommended or sold by

manufacturer. The use of attachments not recom-

mended by the manufacturer may result in fire,

electric shock, or injury.

– SAVE THESE INSTRUCTIONS –

• Do not disassemble charger. Take it to a qualified

service professional if service or repair is required.

Incorrect assembly may result in fire or electrical

shock.

• To reduce risk of electrical shock, unplug the

charger from the outlet before attempting any

maintenance or cleaning.

• Always charge battery in a well ventilated area.

WARNING

• Wear complete eye and clothing protection when

working with lead-acid batteries.

• Be sure that someone is within range of your voice

to come to your aid if needed, while you work with or

are near a lead-acid battery.

• Have plenty of fresh water and soap nearby for

use in case battery acid contacts your eyes, skin, or

clothing. If this happens, wash immediately with

soap and water. Then get medical attention.

• Avoid touching your eyes while working with a

battery. Acid particles (corrosion) may get into your

eyes. If this occurs, flush eyes immediately with

running cold water for at least 10 minutes. Then

immediately get medical attention.

• Remove all personal metal items from your body,

such as rings, bracelets, necklaces, and watches

while working with a lead-acid battery. A battery can

produce a short circuit current high enough to weld a

ring (or the like) to metal, causing a severe burn.

• Take care not to drop any metal tool or metal object

onto the battery. This may spark or short circuit the

battery or another electrical device that may cause

an explosion.

• Always operate your battery charger in an open,

well ventilated area.

• Never smoke or allow a spark or flame in the vicinity

of the battery or engine. Batteries generate explo-

sive gases.

• Neutralize any acid spills thoroughly with baking

soda before attempting to clean up.

• WARNING: Handling the cord on this product or

cords associated with accessories sold with this

product, may expose you to lead, a chemical known

to the State of California to cause cancer and birth

defects or other reproductive harm.

Wash hands

after handling.

Parts

This section shows an illustration of your battery charger. Use it to become familiar with where all the parts are

located, and what they look like.

Replacement Parts List DieHard 71230

Wiring Diagram

Item Description Part Number

1. Handle 3599000286

2. Negative (BLK) Cable w/Clamps 3899000396

3. Positive (RED) Cable w/Clamps 3899000410

4. Power Cord 90026096

5. Circuit Breaker Assembly 3999000099

6. Rectifier Assembly 2299001081

7. Transformer 93026532

8. Fan Motor 0099000063

9. Wheel 0099000080

10. Hub Cap 5200000008

11. Axle 0099000060

12. Axle Mtg. Brackets 1199004366

13. Mounting Foot 1199003352

14. Rocker Switch 3 Position 0499000052

15. Ammeter 5399100088

16. Rocker Switch 2 Position 0499000050

17. Owner's Manual 0099000312

Wiring Diagram 71230

To attach the axle assembly:

1. Remove charger from packing materials and place

upside down on a flat surface. Attach mounting

foot and secure with the two 1/4-20 thread cutting

screws.

2. Hold axle upright on floor or work surface. Then,

using a hammer, tap one of the plastic hubs onto

the top end of the axle. Be sure to tap the hub on

straight. Slide both wheels onto the axle with the

hubs facing inward.

continued on next page

Before Using Your Battery Charger

It is important to prepare your charger for use. This section will tell you how to assemble the charger, ground

and connect the power cord, and prepare to charge a battery.

Assembling your charger

It is important to fully assemble your charger before use.

Follow these instructions for easy assembly.

PARTS: TOOLS NEEDED:

Two 10-32 thread cutting 3/8" wrench

screws (for mounting foot)

Two 1/4-20 thread cutting 5/16" wrench

screws (for wheels)

Two wheels Hammer

One axle Phillips screwdriver

Two axle caps

Two axle brackets

One handle

One mounting foot

3. Place the charger on its side. Place one end of

each bracket into slot, then place the axle assem-

bly under each bracket. Fasten the other side of

the brackets using the two 10-32 screws provided.

To attach the handle:

Turn the charger right side up onto its foot and wheels.

Remove the two top screws from each side of the

charger. Align the handle so the screw holes are

aligned with the screw holes on each side of the wheel

charger. Attach the handle using the same screws.

WARNING

Plugging it in

Electrical Shock Hazard

Be sure that power cord fits properly into outlet.

If not, have a qualified technician install a proper

outlet. Never alter the AC cord or plug provided.

Improper connection can result in electrical shock.

Your charger should be grounded to reduce the

risk of electrical shock.

Your charger is equipped with an electrical cord that

has an equipment grounding conductor and a ground-

ing plug designed to be used on a 120 volt circuit. The

plug must be plugged into an outlet that has been

properly installed and grounded in accordance with all

local codes and ordinances.

A TEMPORARY adapter may be used to connect the

charger to a two-pole outlet if a properly grounded

outlet is not available. Use the adapter ONLY until a

properly grounded outlet can be installed by a qualified

electrician.

MINIMUM RECOMMENDED EXTENSION CORD

Length of Cord, in Feet 25 50 100 150

AWG* Size of Cord 18 14 12 10

*AWG=American Wire Gauge

Preparing your battery to be charged

It is important that you read and follow these guide-

lines while you are preparing to charge your battery.

• Make sure that you have a 12 volt lead-acid battery.

Clean the battery terminals. Be careful to keep

corrosion from getting in or around your eyes.

• If you have a battery with removable cell caps, if

required, add distilled water to each cell until the

battery acid reaches the level indicated by the

manufacturer. This will help purge excessive gases

from the cells. Be careful not to overfill. If you have a

sealed battery without cell caps, no action is neces-

sary. Continue to the next step listed below.

• Take time to read all battery manufacturer’s specific

precautions, such as removing or not removing

cell caps while charging, and recommended rates

of charge.

• Wear safety glasses. See additional "Personal

Safety Precautions" on page 2.

• Be sure that the area around the battery is well

ventilated while it is being charged. If ventilation is

poor, any gases emitted from the battery can be

manually blown away by using a piece of cardboard

or other non-metallic material as a fan.

• If it is necessary to remove the battery from the

vehicle to charge it, always remove the grounded

terminal from the battery first. A spark may be

caused if all accessories in the vehicle are not

completely turned off.

NOTE: A marine battery installed in a boat must be

removed and charged on shore.

Using an extension cord

The use of an extension cord is not recommended. If

you must use an extension cord, please make sure

that you follow these guidelines:

• Make sure the pins on the plug of the extension cord

are the same number, size, and shape as those of

the plug on the charger.

• Use only 3-conductor (grounded) extension cord

when necessary.

• Check that the extension cord is properly wired and

in good electrical condition.

• Use the recommended minimum AWG (American

Wire Gauge) to be sure that wire size is large

enough for the rating of the charger.

WARNING: Improper adapter con-

nection can result in electrical shock.

Before using an adapter as illustrated, be certain that

the center screw of the outlet plate is grounded. The

green colored grounding clip of the adapter must be

attached by a metal screw to a properly grounded

outlet. If unsure whether outlet is properly grounded,

contact a professional electrician. If necessary,

replace the original outlet cover screw with a longer

one that will secure the grounding clip to the outlet

cover and make a ground connection to the grounded

outlet.

To obtain the best results from your battery charger, you must know how to use it properly. This section tells how

to set the controls and how to charge a battery in and out of the vehicle.

Using Your Battery Charger

OFF

40A 12V

CHARGE

2A 12V

CHARGE

200A 12V

ENGINE

START

All the controls for your charger are located on the

front of the unit. Follow these instructions to obtain the

accurate charge level for your battery.

OUTPUT SELECTOR SWITCHES

Two switches are used to select the rate of charge or

function—a 3-position switch on the right, and a 2-

position switch to the left of it. Use the 3-position

switch to select:

•

2 Amp Trickle Charge

— Use for charging small

batteries and warming large batteries. The lower the

charge rate, the longer it will take, but the battery is

subjected to much less stress.

•

OFF

— Leave the switch in the OFF Position while

connecting the charger to the battery and to the AC

power outlet.

• Select — This setting enables you to select one of

the two charge-rate settings offered by the 2-

position switch.

• Use the 40 Amp Charge rate for a fast charge.

• Use the 200 Amp Engine Start for cranking the

engine. Remember that little or no charging has

been done by the charger and, unless your trip is

quite long, your battery will still need further

charging by the vehicle's charging system once

the engine starts.

AMMETER

The AMMETER indicates the measured amount of

amperes being drawn by the battery. When you first

start charging a battery, the reading will be high, with

the needle near 40 at the 40 AMP CHARGE rate. As

the battery charges, the needle will fall to about 15 to

20 amps, indicating a charged battery.

At the 2 AMP CHARGE rate, you will notice very little

needle movement.

When cranking the engine while using the ENGINE

START feature, the needle will swing into the Start

(red) area of the scale.

SELECT

VOLT/AMP SELECTOR

Setting the controls

Charging Your Battery

Charging your battery in the vehicle:

1. Arrange the power cord and charging leads

carefully in order to avoid damage that could be

caused by the hood, door, or moving engine parts.

2. Keep clear of the fan blades, belts, pulleys, and

other parts that can cause injury.

3. Check the polarity of the battery posts using the

identification marks on the battery case: POSI-

TIVE (POS, P, +) and NEGATIVE (NEG, N, -).

4. Identify which battery post is ground or connected

to the chassis. THE NEGATIVE POST IS NOR-

MALLY THE ONE THAT IS GROUNDED.

5. To charge a negative grounded post system:

Connect the red (POSITIVE) charger clamp to the

ungrounded POSITIVE (POS, P, +) post of the

battery. Next, connect the black (NEGATIVE)

clamp to a heavy unpainted metal part of the

chassis or engine block, away from the battery. Do

not connect clamp to carburetor, fuel lines, or

sheet metal parts.

To charge a positive grounded post system:

Connect the black (NEGATIVE) charger clamp to

the ungrounded NEGATIVE (NEG, N, -) post of

the battery. Then connect the red (POSITIVE)

clamp to a heavy unpainted metal part of the

chassis or engine block, away from the battery. Do

not connect clamp to carburetor, fuel lines or

sheet metal parts.

6. Connect the clamp to the battery post and twist or

rock back and forth to make a solid connection.

This will help keep the clamps from slipping off the

posts and causing sparks.

7. Set your charger's right-hand 3-position selector

switch to the OFF position. Then plug the charger's

power cord into a grounded AC wall outlet.

8. Select the desired charge rate. (See "Setting the

Controls" on page 7.)

9. The charger will not stop when the battery is fully

charged. For this reason it is important to check

charging progress frequently. Overcharging can

damage a battery, you must monitor and unplug

charger when battery is fully charged.

10. When the battery is fully charged, the AMMETER

needle will fall to about half the charge rate

selected. For specific positions, see the “Amme-

ter” section of “Setting the Controls” on page 7.

11. When the battery is fully charged, unplug the

charger power cord. Next, set the right-hand

switch to the OFF position.

12. Facing away from the battery, remove the charger

clamp from the chassis first, then from the battery

post or terminal.

13. Clean and store the battery charger in a dry

location.

NEGATIVE GROUNDED SYSTEM

Charging your battery outside the vehicle:

1. Remove the battery from vehicle, making sure to

disconnect grounded terminal first with all power

turned off to the vehicle.

2. Check the polarity of the battery posts as indicated

on the battery case: POSITIVE (POS, P, +) and

NEGATIVE (NEG, N, -).

NOTE: On top-post batteries, the positive battery

terminal usually has a larger diameter than the

negative one.

3. Connect the red (POSITIVE) charger clamp to the

POSITIVE post of the battery. Be sure to rock the

clip back and forth to make a solid connection.

4. Attach at least a 6-gauge (AWG) or a 4-gauge

(SAE) insulated battery cable of at least 24-inches

in length to the NEGATIVE battery post. This

cable will provide a safer connection because any

arcing and sparking will not occur directly over the

battery. (The battery cable is not provided with the

charger, but may be purchased at most automo-

tive accessory outlets.)

5. Take the other end of the 6-gauge (AWG) or a 4-

gauge (SAE) insulated 24-inch cable and, standing

as far away from the battery as possible, connect

the black (NEGATIVE) lead to the free end of the

cable. Be sure to rock the clamp to make a solid

connection. IMPORTANT: Wear safety glasses

and face away from the battery while making the

final connection.

6. Set your charger's right-hand 3-position selector

switch to the OFF position. Then plug the

charger's power cord into a grounded AC wall

outlet.

7. Select the desired charge rate. (See "Setting the

Controls" on page 7.)

8. The charger will not stop when the battery is fully

charged. For this reason it is important to check

charging progress frequently. Overcharging can

damage a battery, you must monitor and unplug

charger when battery is fully charged.

9. When the battery is fully charged, the AMMETER

needle will fall to about half the charge rate

selected. For specific positions, see the "Amme-

ter" section of "Settings the Controls" on page 7.

10. When the battery is fully charged, unplug the

charger power cord before attempting to discon-

nect charger clamps.

11. Facing away from the battery, remove the charger

leads. Remove the NEGATIVE clamp first, then

from the POSITIVE battery post or terminal.

12. Clean and store the battery charger in a dry

location.

2 AMP

2 - 4

4 - 10

11 - 14

14 -18

18 - 35

Calculating charge times

• Marine, or deep-cycle batteries are usually rated in

Reserve Capacity (RC).

• NR means that the charger setting is NOT RECOM-

MENDED.

Find your battery’s rating on the chart below and note

the charge time given for each charger setting. The

times given are for batteries with a 50-percent

charge. Add more time for totally discharged batter-

ies.

CHARGE RATE/CHARGING TIME - HOURS

6-12AH

12 - 32 AH

40 - 60 RC

60 - 85 RC

85 -190 RC

80 RC

140 RC

160 RC

180 RC

BATTERY SIZE/RATING

SMALL

BATTERIES

CAR/TRUCKS

MARINE/DEEP CYCLE

200 - 315 CCA

315 - 550 CCA

550 - 1000 CCA

Motorcycle, garden

tractor, etc.

The Hydrometer or Electronic Method

To find the time needed to fully charge your battery,

determine the battery’s charge level with a hydrometer

or electronic Percent-of-Charge Tester. The following

table will help you convert hydrometer readings to

percent of charge values.

SPECIFIC PERCENT PERCENT OF

GRAVITY OF CHARGE CHARGE NEEDED

1.265 100% 0%

1.225 75% 25%

1.155 25% 75%

1.120 0% 100%

When you know the percent of charge and the Amp

Hour (AH) rating of your battery, you can calculate the

time needed to bring your battery to a full charge.

To convert Reserve Capacity to Amp Hours, divide

Reserve Capacity by 2, and add 16:

Amp Hours = Reserve Capacity + 16

NOTE: The Reserve Capacity can be obtained from

the battery specification sheet or the owner's manual.

To calculate time needed for a charge:

• Find the percent of charge needed. (A battery at 50

percent charge that will be charged to 100 percent

needs another 50 percent (.50).

• Multiply the Amp Hour rating by the charge needed

(.50) and divide by the charger setting (2 or 10

amps).

• Multiply the result by 1.25 and you’ll have the time

needed, in hours, to bring the battery to full charge.

• Add one additional hour for a deep-cycle battery.

Example:

Amp Hour Rating x % of charge needed x 1.25 = hours

Charger Setting of

charge

100 (AH Rating) x .50 (charge needed) x 1.25 = 6.25

40 (Charger Setting) hours

100 x .50 = 1.25 x 1.25 = 1.5625

You would need to charge your 100-Ampere Hour

Battery for approximately 1½ hours at the 40-Amp

charge rate using the above example.

40 AMP

30 to 45 min.

45 min. to 1 hour

1 - 2

The Chart Method

Use the following table to more accurately determine

the time it will take to bring a battery to full charge.

First, identify where your battery fits into the chart.

• Small batteries — motorcycles, garden tractors, etc.

— are usually rated in Ampere Hours (AH). For

example: 6 to 12 AH, or 12 to 32 AH.

• Batteries in cars and smaller trucks are usually rated

in Reserve Capacity (RC), Cold-Cranking Amps

(CCA), or both.

A minimal amount of care can keep your battery

charger working properly for years.

1. Clean the clamps each time you are finished

charging. Wipe off any battery fluid that may have

come in contact with the clamps to prevent

corrosion.

2. Coil the input and output cords neatly when storing

the charger. The cords can be wrapped around

the handle of the charger. This will help prevent

accidental damage to the cords and charger.

3. Occasional cleaning of the case with a soft cloth

will keep the finish shiny and help prevent corro-

sion.

Maintenance and care

Using the engine start feature

Your battery charger can be used to jump-start your

car if the battery is low. Follow these instructions on

how to use the engine start feature.

1. Set the right-hand OUTPUT SELECTOR switch to

the OFF position. Then follow the instructions for

connecting the charger to the battery in the

section “Charging your battery in the vehicle” see

page 8.

2. Once the charger is connected, set the right-hand

selector switch to SELECT and set the left selec-

tor switch to the 200 AMP START position.

3. Plug the power cord into a grounded AC wall outlet.

4. Crank the engine for no more than five seconds.

If the engine does not start, wait four minutes

before cranking again.

5. During extremely cold weather, or if the battery is

severely exhausted, charge the battery for about

five minutes before cranking the engine.

6. If the engine still does not start, charge the battery

for five more minutes in the 40 AMP position

before cranking it again for five seconds.

7. After the engine starts, unplug the charger power

cord from the outlet. Then move the right-hand

SELECTOR SWITCH to the OFF

position before disconnecting the battery leads.

IMPORTANT: Do not try to start the engine without a

battery in it. You could cause damage to the electrical

system.

If the engine does turn over, but never starts up, there

is not a problem with the starting system, there is a

problem somewhere else with the vehicle. STOP

cranking the engine until the other problem has been

diagnosed and corrected.

Troubleshooting

Performance problems often result from little things that you can fix yourself. Please read through this table for a

possible solution if a problem occurs.

PROBLEM POSSIBLE CAUSE SOLUTION/REASONS

No reading on the Clamps are not making a Check for poor connections to battery and frame. Make

ammeter. good connection. sure connecting points are clean.

2-amp charge rate is Ammeter may show no activity at the 2-amp charge rate.

being used.

No reading on No power at receptacle. Check for open fuse or circuit breaker supplying AC outlet.

ammeter. Fan inside

wheel charger appears AC cord and/or extension Check power cord and extension cord for loose fitting

to not be working. cord is loose. plug.

Circuit breaker in Shorted battery clamps. Circuit breaker cycles when current draw is too high.

charger cycles on Separate the clamps.

and off with a clicking Check for worn cables and replace if needed.

sound.

Shorted battery. Have a Sears technician test the battery.

Charger leads reversed. Correct connections.

Volt/Amp Selector Switch Correct Volt/Amp Selector setting.

set to the START position.

Short start cycle Drawing more than 200 Crank time varies with the amount of current drawn. If

when cranking amps for a period of 5 cranking draws more than 200 amps, crank time may be

engine. seconds or less. less than 5 seconds.

Failure to wait for 4 Wait 4 minutes before next crank.

minutes (240 seconds)

between cranks.

Ammeter reads less Extension cord too long Use shorter or heavier gauge extension cord.

than selected charge or wire gauge too small.

rate when charging

a discharged battery. Weak cell or sulfated Sulfated battery will eventually take a normal charge if left

plate in battery. connected. If the battery will not take a charge, have it

tested by a Sears technician.

Battery is only partially Continue charging battery.

discharged.

Charger makes a loud Transformer laminations Continue charging. Buzz is not abnormal.

buzz or hum. vibrate (buzz).

Shorted diode (hum). Have charger tested by a Sears technician.

If the above solutions do not eliminate the problem...

call toll-free from anywhere in the U.S.A.

1-800-SEARS-64

(1-800-732-7764)

7 AM to 4:30 PM Central Time Monday through Friday

For information about troubleshooting, call toll-free from anywhere in the

U.S.A. 7 am to 4:30 pm Central Time Monday through Friday.

1-800-SEARS-64 (1-800-732-7764).

Sears 200.71230, 200.71231 User manual

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